Performance

Spotlight

Kodak:

Optimizing the Pumping System Saves Energy and Reduces 

Demand Charges at a Chemical Plant

Project Summary

Staff at Kodakʼs plant in Rochester, New York, signifi cantly improved the energy 

effi ciency of its two lake-water pumping stations in December 2003. To identify 

areas for effi ciency improvements, Dr. Barry Erickson of Flowserve Corporation, a 

U.S. Department of Energy (DOE) Allied Partner, used the DOE Pumping System 

Assessment Tool (PSAT) to conduct the pumping system assessment. Flowserve 

then proposed a system-level project to increase the pumpsʼ energy effi ciency. The 

project team established a baseline for the performance and energy consumption of 

both stationsʼ pumps. The evaluation indicated energy-effi cient pump combinations 

and other non-capital-intensive energy effi ciency measures that would save energy 

while pumping the required volume of water. Plant personnel then implemented 

several effi ciency measures that improved system performance and yielded 

important energy savings at Kodakʼs Rochester plant. 

Plant/Project Background

The Rochester plant is home to Kodakʼs corporate headquarters, the companyʼs 

largest U.S. manufacturing operation, its corporate services offi ce, and a research 

and development facility. Several years ago, the plantʼs management realized 

that many motor and process systems installed in the 1950s were not operating 

effi ciently. This was occurring because motor and process systems were being used 

to support newer production equipment, which is less energy-intensive (i.e., 

it needs less energy to operate) than the 1950s-era production equipment was. 

The plantʼs lake-water pumping system includes two pumping stations served 

by 12 pumps with an aggregate horsepower (hp) of 7450 hp. Flowserve found 

that many of the pumps had a low ratio of fl ow rate to input power, expressed as 

gallons per minute per kilowatt (gpm/kW). There were also some unnecessary fl ow 

restrictions, and some pumps were operating during peak hours that could operate 

more economically off peak. The pump improvement project included trimming 

impellers, replacing valves, and reconfi guring piping. Plant staff then selected and 

combined pumps that could achieve the highest gpm/kW ratio. 

In addition to improving its pumping systems, Kodak is also using DOEʼs 

MotorMaster+ software tool in its recommissioning program to evaluate the 

performance of motors and processes throughout the Rochester plant. Since the 

programʼs inception, the plant has retrofi tted more than 600 motors (a total of 

11,000 hp) with energy-effi cient motors. These actions are yielding annual energy 

Benefi ts 

• Saves $100,000 annually

• Reduces annual energy 

consumption by nearly 

1.1 million kWh

• Improves performance

• Achieves a 3-month simple payback

Industrial Technologies Program 

Proven Tools and Practices to 

Increase Industrial System Energy Effi ciency

Applications 

Lake-water pumping systems 

that provide process-cooling 

water for industrial plants 

can consume a signifi cant 

amount of energy. Optimizing 

ineffi cient pumping systems 

can save energy, reduce water 

consumption, and minimize the 

need for chemical treatment of 

the lake water. 

Proven Tools and Practices to 

Increase Industrial System Energy Effi ciency

Lake Station high-lift pumps
BestPractices is part of the Industrial 

Technologies Program, and it supports 

the Industries of the Future strategy. 

This strategy helps the country’s 

most energy-intensive industries 

improve their competitiveness. 

BestPractices brings together emerging 

technologies and energy-management 

best practices to help companies 

begin improving energy efficiency, 

environmental performance, 

and productivity right now.

BestPractices emphasizes plant 

systems, where significant efficiency 

improvements and savings can be 

achieved. Industry gains easy access 

to near-term and long-term solutions 

for improving the performance of 

motor, steam, compressed air, and 

process heating systems. In addition, 

the Industrial Assessment Centers 

provide comprehensive industrial 

energy evaluations to small- and 

medium-size manufacturers.

A Strong Energy Portfolio 

for a Strong America

Energy efficiency and clean, renewable 

energy will mean a stronger economy, 

a cleaner environment, and greater 

energy independence for America. 

Working with a wide array of state, 

community, industry, and university 

partners, the U.S. Department 

of Energy’s Office of Energy Efficiency 

and Renewable Energy invests 

in a diverse portfolio of energy 

technologies.

FOR ADDITIONAL INFORMATION, 

PLEASE CONTACT:

EERE Information Center

1-877-EERE-INF

(1-877-337-3463)

www.eere.energy.gov

Visit our home page at

www.eere.energy.gov/industry

Industrial Technologies Program

Energy Efficiency and Renewable Energy

U.S. Department of Energy

Washington, DC 20585-0121

savings of more than 7 million kWh and energy cost savings of approximately 

$500,000 per year.

Results

Modifications made to the plantʼs lake-water pumping system improved its 

efficiency and performance, yielding significant energy savings. The combined flow 

rate of the pumps has been maintained, even though fewer units are operating at any 

one time. As a result, energy consumption and maintenance needs have declined. 

This has yielded annual energy savings of 1,092,000 kWh and energy cost savings 

of $52,000. Because the pumps are being used more optimally and during offpeak hours, annual demand charges are $48,000 lower. With total project costs of 

$25,000, the project had a 3-month simple payback.

Lessons Learned

Using aging and improperly configured industrial pumping systems can waste 

energy and increase maintenance and operating costs. Over time, industrial plants 

acquire more efficient manufacturing processes and equipment, which can reduce 

the loads on supporting systems. Reconfiguring industrial motor systems in 

response to changing demand patterns can save energy and improve productivity. At 

Kodakʼs Rochester plant, selecting efficient pump combinations and reconfiguring 

some pumps greatly improved the efficiency of two pumping stations. Optimizing 

the lake-water pumping system resulted in significant energy and cost savings; 

therefore, Kodak is now evaluating pumping systems at other plants for similar 

opportunities. Projects like this can be implemented in virtually all industrial 

facilities that require lake or river water to meet production and process cooling 

needs.

Project Partners

Eastman Kodak 

Company

Rochester, NY

Flowserve Corporation

Kalamazoo, MI

Partner Profile

Dr. Barry Erickson is a mechanical engineer serving as a Key Account 

Manager for Flowserve Corporation, a DOE Allied Partner. He has more 

than 33 years of experience with industrial pumping systems. He has 

presented papers at technical conferences in the United States and 

Europe, written articles for numerous journals, and holds two patents. 

Currently, he is based at Eastman Kodak’s plant in Rochester, NY.

Allied Partners

The DOE Industrial Technologies Program (ITP) offers many 

opportunities for partnering, such as BestPractices Allied Partnerships 

(www.oit.doe.gov/bestpractices/ap_whatis.shtml). Allied Partners are 

manufacturers, trade associations, industrial service and equipment 

providers, utilities, and other organizations that agree to help promote 

increased energy efficiency and productivity for industries that 

participate in ITP’s Industries of the Future strategy. DOE also provides 

helpful tools for industry’s use in increasing efficiency. One is the 

Pumping System Assessment Tool (PSAT), which uses data on pump and 

motor performance to calculate potential energy and cost savings. For 

information, visit www.oit.doe.gov/bestpractices/software_tools.shtml.

Dr. Barry Erickson

DOE/GO-102005-2082

June 2005